Microwave-assisted TBM cutter for efficient hard rock fracturing in high stress environments

Elucidating the effects and fundamental mechanisms of microwave-assisted mechanical excavation under high initial stress conditions is of paramount importance for enhancing the efficiency of deep resource extraction. In this study, indentation experiments were conducted on microwave-damaged rock under initial stress conditions using a tunnel boring machine (TBM) for the first time. By integrating acoustic emission, digital image correlation, and the discrete element method, we conducted a comprehensive analysis of the multifaceted effects of microwave irradiation and initial stress on rock fracturing. The rock-breaking efficiency was evaluated based on the volume of broken rock and the energy consumption. The indentation failure of the sample can be divided into three stages: microfracture closure, elastic deformation, and unstable crack propagation. The microwave irradiation reduced the peak load during the indentation process and simultaneously reduced the brittleness of the specimen. The experimental and simulation results jointly demonstrated the existence of an initial stress threshold in the rock fracturing process. When the initial stress is below the threshold, it suppresses the extension of rock fractures, which is unfavorable for rock fragmentation. When the initial stress exceeds the threshold, stress-induced rock failure occurs, which promotes rock fragmentation. A notable observation is that microwave irradiation alters the initial stress threshold of the rock, where a higher microwave power correlates with a lower initial stress threshold. This indicates that the optimal parameters for microwave equipment must be reconsidered when the initial stress changes. Methods for optimizing rock breakage at initial stress were suggested and examined.